NCSX Modular Coil Flange Joint Cryogenic Tension Tests …€¦ · I. Superbolt Instructions 17 ......

NCSX Modular Coil Flange Joint Cryogenic Tension Tests Report

Prepared By: ______________________________L. Dudek

NCSX Outboard Shim Cryogenic Tension Tests

of 23 Tuesday, October 7, 2008

Object 4

Summary 4

Introduction 4

Equipment and method 4

Figure 1: Photo Test Setup 4

Figure 2: Photo Foam dewar and test specimens 5

Data and results 6

Figure 3 Stud Tension / Strain Data 7

Table 1: Stud Tension vs Joint Compression Surrogate 1 8




Figure 4: Supernut Torque vs Stud Load 9

Figure 5: Run 1, Stud 1 & Stud 2 Tension vs Temperature 10

Figure 6: Run 2, Stud 1 Tension vs. Temperature 11

Figure 7: Run 2, Stud #2 Tension vs Temperature 12

Figure 8: Run 3 Stud 1 Tension vs Temperature 13

Figure 9: Run 3 Stud 2 Tension vs Temperature 14

Figure 10: Run 4, Stud 1 & 2, G10 Shims, Tension vs LN2 Level 15

Figure 11: Run 5, Stud 1 & 2, G-10 Shims Tension vs Temperature 16

Conclusions and recommendations 16

Appendix A 17

I. Superbolt Instructions 17

II. Data from the Strain Gage Calibration 18

III. Run #1 Data 19



IV. Data from Run #2 20

V. Data from Run #3 22



1. ObjectThe object of these tests was to:

1.Determine deflection of joint under axial preload2.Confirm Supernut torque-load curve and accuracy of Ultrasonic tester3.Determine change in preload when cooled to 80K4.Determine change in preload due to thermal cycling5.Determine change in preload due to relaxation at room temperature

If there is noticeable relaxation at RT, re-tighten the assembly and determine if there is any subsequent change.

Disassemble and inspect the surfaces and edges of the shims for damage2. Summary

Sample joints were prepared using the stock parts fabricated for the modular coil joint and surrogate flange sections made from Stellalloy casting material. The parts were tensioned to 80 kips and tension measurements were taken over time and after thermal cycling to LN2 temperature to determine if relaxation of the joint tension occurs.

Tests were also conducted to develop a torque vs load curve for the Supernut fasteners.3. Introduction

The NCSX Modular Coils are held together using a stud and shim connection. Each of the shims at each stud utilizes a metal core (stainless steel) with a G-10 insulator on each side for electrical isolation. The shear connection requires a tension of 72 kips to ensure that there is compression on the G-10 and stainless steel surfaces to ensure adequate friction forces.4. Equipment and method

Two stud kits were assembled using the parts shown on drawing SE140-090-r2. All of the parts in the load path were used and the two surrogate flange surfaces were fabricated using 1.5” thick Stellalloy material taken from one of the NCSX Prototype castings. The first two assemblies were tested using alumina coated (by White Engineering) shims. One of the assemblies used a threaded surrogate flange (stud #1) and the other assembly was through bolted using a hexnut on one end and a Supernut on the other (stud #2). All of the washers and shims were production articles. Each stud was fitted with a resistance strain gage to measure the strain directly.

Figure 1: Photo Test Setup



The cryogenic tests were conducted in a foam insulated dewar fabricated especially for these tests. Temperature compensation was accomplished using a thermocouple mounted to a dummy stud inside the dewar cavity. The test articles were mounted about 1-2” above the floor of the dewar.

Figure 2: Photo Foam dewar and test specimensThe long stud was tensioned in the 100 kip MTS machine to 80-85 kips to derive the

calibration curve (Figure 3) for load vs strain indication on the strain gages. A compensating gage was used on the short stud. The test was conducted by running the load up to 85 kips and back down to zero (0) kips while reading the strain gage values using a bridge.

The stud kits and surrogate flanges were then assembled using the assembly sequence shown on the drawing. The Supernuts were torqued to achieve 80-85 kips and were verified using the calibrated strain gages attached to each stud. Torques were applied using a “click” type torque wrench set to the indicated values. Note that later calibration of the torque wrench against a standard indicated a 4 ft-lb offset. The torquing method used was that specified in the Supernut assembly instructions. Measurments on the outside corners of the surrogate flanges were taken as the parts were tensioned to get an indication of how much the joint compressed under load. The data recorded for each assembly is shown on Tables 1 through 4.

Once the parts were properly torqued they were mounted inside the LN2 dewar as shown in Figure 2 and cooled to 77 K using liquid nitrogen. The first run was cooled by flooding the volume around the test specimens with LN2 to quickly bring the parts down to temperature. For the first run a reference TC junction was not installed so the temperatures recorded for the first test were approximate for indication only.

MTS MachineMTS Systems Corp.10 Kip servo-hydraulic tension and compression testing machineModel 204.61Serial # 245Load cellMTS Systems Corp.



Model 661-21A-02Serial # 1273Calibrated 02/12/07 Strain Gage BridgeVishay model P-350A portable strain indicator

5. Data and resultsThe data taken during the test runs is provided in the Appendix. The first Run (Figure 5) was

taken using a thermocouple without a reference junction so the temperatures are approx. The pieces were cooled by flooding with LN2. This chilled the parts quickly and provided a worst case scenario. The tension in the studs rose quickly during the transients but returned to near starting tensions once at LN2 temperatures and then again once warmed back up to room temperature. The second test run (Figures 6 & 7) was conducted using a fairly slow cooldown (approximately 8 hrs) to demonstrate a more realistic scenario for the tension in the joint. As expected the tension spike initially but quickly returned to normal values. Upon warming to room temperature the tension returned to the baseline value. The third run (Figures 8 & 9) was a repeat of the second test but was only held conducted using a similar cooldown rate but was held at temperature for 3 days. All of the first 3 runs were conducted with the alumina coated shim. The last 2 runs #4 & 5 (Figures 10 & 11) were conducted using the G-10 / SS sandwich style shims.



Figure 3 Stud Tension / Strain Data

Torque Corner 1 (inches)

Corner 2 Corner 3 Corner 4 μStrain Stud Tension (Kips)

0 ft-lb 4.02 4.018 4.025 4.02 0 0.00

19 4.016 4.017 4.019 4.018 1012 40.80

0 20 40 60 80

0

500

1000

1500

2000

2500

Load (Kips)

Stu

d M

icro

str

ain

(!

in

/ i

n)

Stud Tension vs Strain Data

Microstrain Run #1

MicroStrain Run #2





33 4.016 4.017 4.018 4.018 1780 72.07

38 4.016 4.017 4.018 4.018 1968 79.72

Table 1: Stud Tension vs Joint Compression Surrogate 1



0 ft-lb 3.764 3.765 3.763 3.765 0 0.00

19 3.762 3.763 3.762 3.762 1038 41.86

33 3.762 3.763 3.762 3.762 1784 72.23

38 3.762 3.763 3.762 3.762 2038 82.57




0 ft-lb 4.04 4.042 4.043 4.045 0 0.00

19 4.043 4.042 4.044 4.044 1134 45.77

33 4.042 4.042 4.044 4.045 1714 69.38

38 4.042 4.042 4.044 4.045 1924 77.93




0 ft-lb 3.788 3.786 3.787 3.788 0 0.00

19 3.788 3.786 3.787 3.788 1214 49.02

33 3.788 3.786 3.787 3.788 2074 84.03

38 3.788 3.786 3.787 3.788 2324 94.21



Figure 4: Supernut Torque vs Stud Load



0 5

10

15

20

25

30

35

40

0

10

20

30

40

50

60

70

80

90

Torque (ft–lb)

Tensio

n K

ips

Supernut Torque vs Stud Load

Figure 5: Run 1, Stud 1 & Stud 2 Tension vs Temperature



30

–N

ov 1

7:5

5

30

–N

ov 1

8:0

0

30

–N

ov 1

8:0

5

30

–N

ov 1

8:1

0

30

–N

ov 1

8:1

5

30

–N

ov 1

8:1

7

30

–N

ov 1

8:2

0

30

–N

ov 1

8:2

5

30

–N

ov 1

8:3

0

30

–N

ov 1

8:3

5

30

–N

ov 1

8:4

0

30

–N

ov 1

8:4

5

30

–N

ov 1

8:5

0

3–

De

c 1

0:0

0

3–

De

c 1

5:0

0

3–

De

c 1

7:3

0

4–

De

c 9

:30

0

40

80

120

160

200

–10.00

0.00

10.00

20.00

Date & Time

Kip

s

Run 1Strain vs Time, Temperature

Micro Strain 1

Micro Strain 2

Tc1

TC

ou

tpu

t in

mil

liv

olt

s(u

nc

om

pe

ns

ate

d T

C)

Boiling Stopped

Figure 6: Run 2, Stud 1 Tension vs. Temperature



0

20

40

60

80

100

–200.0

–100.0

0.0

100.0

200.0

60

70

80

90

100

110

120

Time (Hours)

Stu

d L

oad

(K

ips)

Load vs Temp. Data Stud 1, Run 2(thru hole flange)

Stud Temperature (deg. C)

Stud Load (Kips)

Stu

d T

em

p. (d

eg

. C

)

Figure 7: Run 2, Stud #2 Tension vs Temperature



0 20 40 60 80 100–200.0

–100.0

0.0

100.0

200.0

60

70

80

90

100

110

120

Time (Hours)

Stu

d L

oad

(K

ips)

Load vs Temp Data Stud 2, Run 2(threaded flange)

Stud Temperature (deg. C)

Stud Load (Kips)

Stu

d T

em

pera

ture

(d

eg

. C

)

Figure 8: Run 3 Stud 1 Tension vs Temperature



0

10

20

30

60

70

80

90

100

110

120

–200.0

–100.0

0.0

100.0

200.0

60

70

80

90

100

110

120

Time (hours)

Stu

d T

en

sio

n (

Kip

s)

Run 3 Stud 1 Tension vs Temp(thru hole flange)

Run 3 Kips 1

Run 3 Temp Stud 1 (deg C)

Tem

pera

ture

(d

eg

. C

)

0

10

20

30

60

70

80

90

100

110

120

–200.0

–100.0

0.0

100.0

200.0

60

70

80

90

100

110

120

Time (hours)

Stu

d T

en

sio

n (

Kip

s)

Run 3 Stud 2 Tension vs Temp(threaded hole flange)

Run 3 Kips 2

Run 3 Stud 2 (deg C)

Te

mp

era

ture

(d

eg

. C

)

Figure 9: Run 3 Stud 2 Tension vs Temperature



Figure 10: Run 4, Stud 1 & 2, G10 Shims, Tension vs LN2 Level



0 2 4 6

80

100

120

140

0.0

4.0

8.0

12.0

Time (Hours)

Stu

d #

1 T

ensio

n (

Kip

s)

Run 4 G10 Shims Stud #1 & #2 Tension vs LN2 Level

Stud #1 Tension (Kips)

Stud #2 Tension (Kips)

LN2 Level

LN

2 L

iquid

Level

Figure 11: Run 5, Stud 1 & 2, G-10 Shims Tension vs Temperature6. Conclusions and recommendations

The tests demonstrated that both the alumina and G-10 sandwich style shims maintain tension during a cooldown cycle and return to room temperature. No significant changes in the parts were observed upon disassembly and inspection after completion of the tests.



0 10 20 300

50

100

150

–200.0

–100.0

0.0

100.0

200.0

300.0

Time (Hours)

Tensio

n K

ips

Run 5 G10 Shims Stud #1 & #2 Tension vs TIme

Stud 1 Kips

Stud 2 Kips

Stud 1 Temp C

Stud 2 Temp C

7. Appendix AI. Superbolt Instructions



II. Data from the Strain Gage Calibration

Load (Kips) Microstrain Run #1

MicroStrain Run #2

Calculated Kips

00.5151015202530354045505560657075808580706050403020100.5

0 0 -0.4016 20 0.4128 36 1.07

120 128 4.81244 248 9.70370 370 14.66492 494 19.71616 618 24.76738 742 29.81862 866 34.86982 994 40.07

1110 1120 45.201230 1240 50.081350 1360 54.971470 1480 59.851590 1600 64.741710 1720 69.621840 1840 74.511960 1970 79.802080 2090 84.691960 1970 79.801730 1730 70.031500 1500 60.671260 1260 50.901020 1020 41.12766 764 30.70514 510 20.36258 258 10.1020 20 0.41



III. Run #1 Data

Date & Time Micro Strain Stud 1

Kips Stud 1

Micro Strain Stud 2

Kips Stud 2

Tc1 Tc2 Notes

Nov 30, 2008 5:55 PMNov 30, 2008 6:00 PMNov 30, 2008 6:05 PMNov 30, 2008 6:10 PMNov 30, 2008 6:15 PMNov 30, 2008 6:17 PMNov 30, 2008 6:20 PMNov 30, 2008 6:25 PMNov 30, 2008 6:30 PMNov 30, 2008 6:35 PMNov 30, 2008 6:40 PMNov 30, 2008 6:45 PMNov 30, 2008 6:50 PM

Dec 3, 2008 10:00 AM

Dec 3, 2008 3:00 PMDec 3, 2008 5:30 PMDec 4, 2008 9:30 AM

1978 80.13 2000 81.02 -0.1 -0.2 Start of LN2 pour1994 80.78 2110 85.50 -0.1 -0.22122 85.99 2256 91.44 0 -0.42374 96.25 2558 103.74 -0.4 -0.83776 153.32 4006 162.69 -0.7 -1.23616 146.81 3922 159.27 -1.4 -1.63560 144.53 3850 156.34 -3.3 -3.12038 82.57 2294 92.99 -6.4 -10.11872 75.81 2040 82.65 -10.1 -10.11866 75.57 2034 82.41 -10.1 -10.11866 75.57 2034 82.41 -10.1 -10.11874 75.89 2042 82.73 -10.1 -10.11874 75.89 2042 82.73 -10.1 -10.1 Test Concluded, left

in LN2 over weekend

1818 73.61 1864 75.48 -6.1 -6.1 In Chamber , warming up

1864 75.48 1910 77.36 -3.3 -3.2 Warming up1912 77.44 1954 79.15 -2.2 -2.2 Warming up1946 78.82 1988 80.53 -0.5 -0.5 Warming up



IV. Data from Run #2

Date & Time Time (Hours)

MicroStrain 1

Kips 1 Microstrain 2

Kips 2 Temp Stud 1 (deg. C)

Temp Stud 2

(deg. C)Dec 6, 2007 10:05 AMDec 6, 2007 10:15 AMDec 6, 2007 10:30 AMDec 6, 2007 10:45 AMDec 6, 2007 11:15 AMDec 6, 2007 11:22 AMDec 6, 2007 11:30 AMDec 6, 2007 11:45 AMDec 6, 2007 12:00 PMDec 6, 2007 12:30 PMDec 6, 2007 12:46 PMDec 6, 2007 12:53 PMDec 6, 2007 1:00 PMDec 6, 2007 1:30 PMDec 6, 2007 1:35 PMDec 6, 2007 1:46 PMDec 6, 2007 2:00 PMDec 6, 2007 2:15 PMDec 6, 2007 2:21 PMDec 6, 2007 2:30 PMDec 6, 2007 2:46 PMDec 6, 2007 3:00 PMDec 6, 2007 3:06 PMDec 6, 2007 3:15 PMDec 6, 2007 3:30 PMDec 6, 2007 3:45 PMDec 6, 2007 4:00 PMDec 6, 2007 4:08 PMDec 6, 2007 4:15 PMDec 6, 2007 4:30 PMDec 6, 2007 4:45 PMDec 6, 2007 5:00 PMDec 6, 2007 5:06 PMDec 6, 2007 5:15 PMDec 6, 2007 5:30 PMDec 7, 2007 9:15 AMDec 7, 2007 10:15 AMDec 7, 2007 11:30 AMDec 7, 2007 12:30 PMDec 7, 2007 1:30 PMDec 7, 2007 2:30 PM

0 1956 79.23 2040 82.65 19.7 19.60.17 1850 74.92 2412 97.79 17.4 18.10.42 1889 76.50 2362 95.76 2.8 7.10.67 1896 76.79 2396 97.14 -9.5 0.51.17 1882 76.22 2444 99.10 -24.4 -10.91.28 1894 76.71 2606 105.69 -29.2 -15.11.42 1872 75.81 2616 106.10 -39.4 -21.11.67 1746 70.68 2616 106.10 -75.6 -30.91.92 1684 68.16 2614 106.02 -89.2 -39.62.42 1624 65.71 2608 105.77 -102.4 -51.42.68 1600 64.74 2596 105.29 -107.7 -57.8

2.8 1632 66.04 2744 111.31 -112.1 -61.42.92 1588 64.25 2736 110.99 -121.2 -68.43.42 1530 61.89 2714 110.09 -140.3 -86.6

3.5 1580 63.92 2770 112.37 -142.3 -90.33.68 1574 63.68 2688 109.03 -152.2 -109.43.92 1562 63.19 2534 102.76 -161.4 -135.04.17 1550 62.70 2542 103.09 -167.7 -139.44.27 1608 65.06 2568 104.15 -170.0 -142.74.42 1610 65.14 2438 98.85 -175.3 -160.04.68 1618 65.47 2374 96.25 -180.9 -173.04.92 1628 65.88 2350 95.27 -184.3 -179.15.02 1672 67.67 2360 95.68 -185.4 -171.35.17 1686 68.24 2384 96.65 -187.3 -183.85.42 1702 68.89 2390 96.90 -188.9 -186.75.67 1704 68.97 2390 96.90 -189.7 -187.95.92 1696 68.65 2374 96.25 -190.0 -188.56.05 1700 68.81 2350 95.27 -193.4 -193.66.17 1724 69.79 2384 96.65 -193.4 -193.76.42 1740 70.44 2400 97.31 -193.4 -193.56.67 1742 70.52 2400 97.31 -193.4 -193.46.92 1742 70.52 2400 97.31 -193.4 -193.27.02 1750 70.84 2402 97.39 -193.4 -193.47.17 1750 70.84 2416 97.96 -193.2 -193.37.42 1750 70.84 2416 97.96 -193.1 -193.0

23.17 1624 65.71 2364 95.84 -179.5 -170.324.17 1620 65.55 2364 95.84 -178.1 -168.425.42 1534 62.05 2290 92.83 -172.4 -160.226.42 1510 61.07 2268 91.93 -165.9 -152.927.42 1510 61.07 2262 91.69 -159.4 -145.528.42 1556 62.95 2246 91.04 -147.1 -137.9



Date & Time Time (Hours)

MicroStrain 1

Kips 1 Microstrain 2

Kips 2 Temp Stud 1 (deg. C)

Temp Stud 2

(deg. C)Dec 10, 2007 9:30 AM 95.42 1942 78.66 2030 82.24 19.3 19.2



V. Data from Run #3

Date & Time Time (hours)

MicroStrain 1

Kips 1 MicroStrain 2

Kips 2 Temp Stud 1 (deg C)

Stud 2 (deg C)

LN2 Level

Dec 10, 2007 10:30 AMDec 10, 2007 10:45 AMDec 10, 2007 11:00 AMDec 10, 2007 11:15 AMDec 10, 2007 11:45 AMDec 10, 2007 12:00 PMDec 10, 2007 12:12 PMDec 10, 2007 12:40 PMDec 10, 2007 12:45 PMDec 10, 2007 1:00 PMDec 10, 2007 1:15 PMDec 10, 2007 1:30 PMDec 10, 2007 1:45 PMDec 10, 2007 2:00 PMDec 10, 2007 2:15 PMDec 10, 2007 2:30 PMDec 10, 2007 2:45 PMDec 10, 2007 3:00 PMDec 10, 2007 3:15 PMDec 10, 2007 3:30 PMDec 10, 2007 3:45 PMDec 10, 2007 4:00 PMDec 10, 2007 4:15 PMDec 10, 2007 4:30 PMDec 10, 2007 5:00 PMDec 11, 2007 11:45 AMDec 11, 2007 12:15 PMDec 11, 2007 4:00 PMDec 12, 2007 10:00 AMDec 12, 2007 10:30 AMDec 12, 2007 1:00 PMDec 12, 2007 5:00 PMDec 12, 2007 5:25 PMDec 13, 2007 10:00 AMDec 13, 2007 11:15 AMDec 13, 2007 12:00 PMDec 13, 2007 1:05 PMDec 13, 2007 2:15 PMDec 13, 2007 3:15 PMDec 13, 2007 4:10 PMDec 13, 2007 5:00 PM

0.00 1956 79.23 2054 83.22 20.1 20.00.25 1948 78.90 2050 83.06 20.5 20.3 0.00.50 1996 80.86 2200 89.16 10.1 10.6 0.40.75 2066 83.71 2320 94.05 -11.6 -6.6 1.31.25 2090 84.69 2406 97.55 -34.1 -19.4 2.01.50 1998 80.94 2492 101.05 -81.4 -39.1 2.51.70 1954 79.15 2516 102.03 -99.6 -50.5 2.82.17 1894 76.71 2550 103.41 -121.6 -71.1 3.02.25 1878 76.06 2550 103.41 -129.9 -79.5 3.12.50 1862 75.40 2548 103.33 -136.9 -88.6 3.42.75 1836 74.35 2526 102.44 -155.4 -110.5 3.63.00 1842 74.59 2250 91.20 -166.7 -152.0 3.83.25 1870 75.73 2182 88.43 -178.2 -169.1 4.13.50 1884 76.30 2164 87.70 -186.9 -182.0 4.83.75 1856 75.16 2148 87.05 -193.4 -187.8 5.34.00 1898 76.87 2128 86.23 -193.5 -194.0 5.84.25 1918 77.68 2144 86.88 -193.5 -194.0 6.54.50 1924 77.93 2150 87.13 -193.5 -194.0 7.04.75 1928 78.09 2154 87.29 -193.4 -193.9 7.45.00 1930 78.17 2156 87.37 -193.4 -193.9 8.05.25 1930 78.17 2156 87.37 -193.4 -193.9 8.55.50 1930 78.17 2156 87.37 -193.5 -193.9 9.15.75 1930 78.17 2156 87.37 -193.4 -193.9 9.66.00 1930 78.17 2156 87.37 -193.4 -193.8 10.06.50 1930 78.17 2156 87.37 -193.4 -193.8 20.0

25.25 1930 78.17 2144 86.88 -194.9 -194.9 9.025.75 1930 78.17 2150 87.13 -194.1 -194.4 13.529.50 1930 78.17 2150 87.13 -195 -194.4 14.547.50 1930 78.17 2150 87.13 -194.1 -195.248.00 1926 78.01 2154 87.29 -194.9 -194.450.50 1924 77.93 2156 87.37 -194.9 -195.054.50 1930 78.17 2160 87.54 -195 -195.154.92 1930 78.17 2160 87.54 -194.1 -194.571.50 1930 78.17 2160 87.54 -194.9 -195.172.75 1930 78.17 2150 87.13 -193.7 -194.073.50 1930 78.17 2148 87.05 -193.5 -193.974.58 1930 78.17 2146 86.97 -193.6 -193.975.75 1930 78.17 2140 86.72 -193.5 -194.076.75 1930 78.17 2140 86.72 -193.5 -193.977.67 1930 78.17 2130 86.31 -193.5 -194.078.50 1930 78.17 2130 86.31 -193.4 -194.0



Date & Time Time (hours)

MicroStrain 1

Kips 1 MicroStrain 2

Kips 2 Temp Stud 1 (deg C)

Stud 2 (deg C)

LN2 Level

Dec 14, 2007 9:15 AMDec 14, 2007 1:00 PMDec 14, 2007 3:30 PMDec 14, 2007 5:15 PMDec 17, 2007 10:00 AMDec 17, 2007 1:00 PM

94.75 1610 65.14 1960 79.39 -167.6 -150.798.50 1694 68.56 1958 79.31 -143.1 -133.7

101.00 1722 69.70 1976 80.04 -133.1 -125.1102.75 1676 67.83 1850 74.92 -112.9 -109.2167.50 1960 79.39 2064 83.63 18.1 18.1170.50 1960 79.39 2056 83.30 20 19.9



NCSX Modular Coil Flange Joint Cryogenic Tension Tests …€¦ · I. Superbolt Instructions 17 ......

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Transcript of NCSX Modular Coil Flange Joint Cryogenic Tension Tests …€¦ · I. Superbolt Instructions 17 ......